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Evaluation of Coatings to Improve Steel Compatibility in Supercritical CO2

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Supercritical CO2 (sCO2) has many attractive features as a working fluid including its low critical point (31°C/73.8 bar) and the reduced work of compression compared to an ideal gas. Thus, it is being explored for many different applications including fossil, nuclear, geothermal, concentrating solar power (CSP) and waste heat recovery. However, CO2 environments are known to carburize steels6-20 which limits their usage to lower temperatures (450°C21 for 9%Cr steels) than in steam boilers.

Product Number: 51323-19207-SG
Author: B. A. Pint, R. Pillai, J. R. Keiser
Publication Date: 2023
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The use of a direct-fired supercritical CO2 (sCO2) power Allam cycle could revolutionize fossil energy as a low-emission power source. However, the carburizing sCO2 environment may limit the use of lower cost steels in the lower temperature portions of the plant because of concerns about embrittlement. Initial studies on representative ferritic-martensitic (FM) steels and conventional and advanced austenitic steels at 450-650°C in 300 bar (30 MPa) sCO2 with and without 1%O2 and 0.1%H2O additions have indicated that sCO2 environments will have lower maximum operating temperatures compared to steam plants. In this study, pack coated steels were evaluated including chromizing and aluminizing. Initial 500-1000 h results showed some benefit of coating especially for the Cr coatings at 600° and 650°C. Characterization included measuring the post-exposure room temperature tensile properties to assess the coating effect on embrittlement typically associated with carbon ingress.

The use of a direct-fired supercritical CO2 (sCO2) power Allam cycle could revolutionize fossil energy as a low-emission power source. However, the carburizing sCO2 environment may limit the use of lower cost steels in the lower temperature portions of the plant because of concerns about embrittlement. Initial studies on representative ferritic-martensitic (FM) steels and conventional and advanced austenitic steels at 450-650°C in 300 bar (30 MPa) sCO2 with and without 1%O2 and 0.1%H2O additions have indicated that sCO2 environments will have lower maximum operating temperatures compared to steam plants. In this study, pack coated steels were evaluated including chromizing and aluminizing. Initial 500-1000 h results showed some benefit of coating especially for the Cr coatings at 600° and 650°C. Characterization included measuring the post-exposure room temperature tensile properties to assess the coating effect on embrittlement typically associated with carbon ingress.

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(Insulation & Corrosion) Insulative Coatings - Fit for Purpose

Product Number: 17-COAT_DEC21
Author: Arin Shahmoradian
Publication Date: 2021
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Corrosion Under Insulation (CUI) is a very serious problem impacting the oil and gas, petrochemical, power and heavy industries. Due to the high costs associated with CUI, many industries have begun abandoning conventional jacket insulation. Recent advancements in trade association standards have helped engineers select, apply and inspect different types of insulative coatings in lieu of conventional jacket insulation.
Picture for Corrosion of Carbon Steel in Supercritical CO2/H2S and Its Mitigation Using Coatings
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Corrosion of Carbon Steel in Supercritical CO2/H2S and Its Mitigation Using Coatings

Product Number: 51319-12768-SG
Author: Shiladitya Paul
Publication Date: 2019
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Carbon steels are widely used in the oil and gas exploration and production service. These steels are prone to corrosion in CO2 and cracking in H2S. The propensity to cracking increases when high strength grades are employed. The use of corrosion resistant alloys incurs costs and only when these costs are justified can such materials be used in industrial service. If these materials can be coated by an industrial method onto carbon steel then their industrial uptake can be increased. To understand the behaviour of CRA coatings on steel several carbon steel coupons were sprayed using high velocity oxy-fuel (HVOF). Carbon steel specimens with and without CRA coatings were then tested in de-aerated 1000mg/L Cl- solution for 30 days bubbled with 10MPa CO2 at 40°C. In some cases tests were also carried out in supercritical CO2 containing 0.1MPa H2S. Microstructural characterization revealed that the carbon steel formed different scales siderite in pure 10MPa CO2 and mackinawite in CO2 containing 0.1MPa H2S. CRA coatings protected the steel substrate from CO2 corrosion when undamaged and no scale was seen.It was concluded that thermally sprayed CRA coatings can provide a cost-effective corrosion mitigation method for infrastructure likely to be in contact with wet supercritical CO2at 40°C. The scales formed on the steel somewhat protected it from further corrosion in 10 MPa CO2. However it was evident that care must be taken to ensure that the thermally sprayed CRA layer does not have any through porosity or defect; else such coatings may accelerate corrosion of the underlying steel substrate due to galvanic interactions.
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A comparison among different electrochemical hydrogen charging methods tested on low alloy steels

Product Number: 51323-18866-SG
Author: Luca Paterlini, Luca Casanova, Giorgio Re, Marco Ormellese, Fabio Bolzoni
Publication Date: 2023
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Atomic hydrogen can enter metallic microstructures from deposition processes like Cr plating or phosphatizing, chemical and electrochemical pickling treatments, during welding operations if the humidity of consumables is too high, by cathodic processes resulting from corrosion phenomena or contact with high pressure gaseous hydrogen. According to different chemical-physical mechanisms, atomic hydrogen can enter the metallic structure resulting in damages of various forms, such as HIC (hydrogen induced cracking), SOHIC (stress oriented HIC), delayed fracture and hydrogen embrittlement (HE).
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